HPN Paris Dakar replica

[Lornce]

Originally Posted by adventure950

Hi Rob I know of Richie Moore so thanks for the pointer -I have in the past spoken to him, he however is going in a different direction to me on the engine front - he is trying to create a race engine from an Airhead something that has been done before in many different ways - me I just want to maximise the torque and like lots of low down power which suits off road riding best for my style (read that as pretty slow) and I want a twin shock HPN style bike not a mono which is his route on this type of build - his engines revolve around outright power and do not really develop any more torque than my set up before 5200 revs - I have owned a KTM 950 which does exactly that and probably far better than the Boxer ever could - I found I did not have big enough Gonads to ride that beast anywhere near its capabilities but it was not the best bike for slow technical stuff - well not for me anyway - the Boxer I think is far better and easier bike to ride on gravel and dirt - that is if like me your not into outright speed. I found Richie was however quite negative about other peoples approaches to engineering, ideas or methods - which is a shame because we all have our own way no one way is correct. He is however a knowledgable and affible bloke and a handy contact with his own specialisation and as you say he is putting his money down on the table and not just talking.

I'm thinking airheads are easier to ride fast on gnarly gravel roads because of their lower centre of gravity. I liked the power and chassis competence of the big KTM's, but the GS slides more naturally and controlably. Like yourself, I built my 1050 motor for midrange, which is where I spend 95% of my riding time.

Not even sure if I've ever red-lined that motor on purpose?

[adventure950]

started trying to work out a wiring diagram to build up a simpler wiring harness, get rid of all the crap, I have decided to use an r80 ignition key, and handle bar switches along with the a few of the relays as a basis and do all the joining up in between myself. They have the simpler switches than the 91 series gs and far more basic wiring like start and kill switch on one side and lights and indicators the other side. there is only the headlight, indicator and starter relays needed and lots less wires as I am stripping out all the airhead charging and ignition systems anyway as I have the endurolast alternator and ignition, I also have Acewell digital speedo with warning lights It means loads of the BMW stuff is not needed in the harness. I may fit some LEd bits as I start the build . This is my working out to scale table - a bit of wallpaper and some kids coloured pencils - you can tell I'm really hi tech eh. That said if I can build it then I can fix it more so in some backwater off the beaten track I will know whats what.

[adventure950]

Here we go a few more pics of the chassis progress, first picture shows the bracing to the right rear tube and the frame footrest hanger cut away this has also been done like the tank hanger with a neat return welded onto its cut edge to give a nice profiled edge to the rear. A new brake lever is presently being manufactured it rotates around a metal tubed hard nylon bush. The top of the new lever is just showing behind being built to fit. The bottom part will cosist of a metal plate with the exposed length of lever bolted onto the mechanism so it can be easily repaired or replaced if damaged, its also easier to carry a short part lever as a spare when away on a trip out.

[adventure950]

This one shows the left side swing arm area brace welded in place

[adventure950]

Next one you can see the tank hung in place and see the finished off tank hanger brackets now all neat and tidy, the headstock side plates are welded in place as well as the original plates having been stitched to the frame downtubes with 30mm welds underneath the inside edges of the plates.

[adventure950]

The rear of the headstock done a bit different to HPN, a saddle was fitted onto the rear top tube and an arrohead plate with a slight ridged back welded onto the saddle then the arrowhead welded to the two uptubes, after evrything was cooled down and checked for alignment or pulling the saddle was welded to the spine tube. On the rear edge of the headstock side frame plates some start / finish indents are apparant htis is because to prevento much heat build up the plates were stitch welded then the stitches in filled - these will be tidied up before coating.

[adventure950]

The left side mid area frame plate joining the two upper and lower spine tube area.

[adventure950]

This is a view of the rear frame bracing and the tank mounting areas, the tank fits perfect - better than when I used the HPN bolt on tank fitting kit, the tank sits really neatly and is clear of the top frame rail and makes no contact with any of the chassis except at its mounting points. It is very secure with no movement.

[adventure950]

Another one of one of the tank hangers - big difference to the original flat plate cut outs neat returns and profiled.

[Deadly99]

[hardwaregrrl]

Wow! That is some serious welding!!!! Thanks for keeping us along!

[adventure950]

Bit of an up shot into the underneath of the side plates, A 'V' shape was cut into the leading edge of the original plates and the new plates and a welded seam put into this area this gives 6 mm of plating to the sides of the headstock, then the original inner plates are stitched to the down tubes on the front edge of the tubes. you can also see a bit of the saddle edges on the spine tube this goes right forward into the rear of the headstock along the edges of the spine tube. The spine tube is excellent quality however a lot of the link tubes used by bmw seem to be thinner than 3 mm and are not as strong as the main tubes.

[Deadly99]

And then......

[adventure950]

been busy I am afraid but the oil cooler hangers done and a few other bits, it the swing arm next but you people just need to hang in there am afraid. forgot to take the camera down the workshop. Starting the wiring harness this week its like sorting out a monkeys nest

[adventure950]

Bye the way I will be selling a used 43 litre tank, HPN tank fitting kit a HPN front bar to fit r80/100gs to allow the tank to be mounted and a pair of fairing side panels so the whole lot goes onto an R80/100gs looks like this picture when all done but the tank for sale is white none paintable the side panels are done in white primer, and the frontbar in black stove enamel. Make me an offer for the the lot plus postage. if anyones interested. Be available september time.